Bulked continuous filament carpet yarn

Abstract

A bi-component, multifilament synthetic dyeable carpet face yarn that is manufactured using the sheath-core melt spinning process is constructed so as to include a plurality of individual uniformly sheath-cored filaments having a sheath of virgin polyamide (e.g., nylon) and a polymer core that cannot be dyed using standard atmospheric pressure carpet dyeing methods used to dye the sheath filaments. This yarn is a less expensive substitute for 100% polyamide tufted carpet face yarn.

What is claimed is: 
     
       1. A carpet tufted with a bulked continuous filament carpet face yarn, wherein said yarn comprises: a) a bundle of drawn and crimped bi-component filaments;   b) each filament consisting essentially of an outer sheath of nylon surrounding a core consisting of fiber forming polymeric material;   c) said nylon sheath constituting from twenty to fifty percent of the total weight of each filament wherein said polymeric core constitutes the remainder of the total weight of each filament;   d) said nylon sheath being dyed under standard atmospheric pressure using nylon dye techniques and said polymeric core material being undyeable under standard atmospheric pressure using said nylon dye techniques;   e) wherein the percentages of nylon and polymeric material in combination impart the properties of recovery from crushing or compression; the ability   to be tufted at high speeds; the ability to apply desired color on conventional dyeing equipment at atmospheric pressure; strength to resist heavy foot traffic; and good bulking properties equivalent to those of a bulked continuous filament carpet face yarn consisting of 100% nylon.   
     
     
       2. The carpet according to claim 1 wherein said polymeric core consists of fiber forming material that is a material not ordinarily used in the manufacture of piece-dyable carpet yarn. 
     
     
       3. The carpet face yarn according to claim 1 wherein said polymeric core material is fiber-forming polypropylene. 
     
     
       4. The carpet face yarn according to claim 1 wherein said polymeric core material is fiber-forming polyethelene terephthalate.